Master Lock MGH4000CI, MGH5000CI, MGH5000CIE, MGH6000CI, MGH7000CI Maintenance And Repairs

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PORTABLE GASOLINE GENERATORS

MAINTENANCE AND REPAIRS

WARNING: Only a qualified electrical service person should service and repair the alternator on this generator. Use only fac- tory approved replacement parts.

CAUTION: The engine speed is preset. The throttle is locked in preset position. Do not adjust throttle. Preset position lets en- gine run at 3600 RPM under load. The engine must maintain 3600 RPM for generator to create cor- rect voltage. Running engine at lower speeds will damage gen- erator and powered items.

CAUTION: Shut off generator before performing maintenance.

IMPORTANT: Keep generator level when servicing. Never turn generator upside down or stand it on end to service.

Note: We supply the engine owner’s manual with generator. Refer to that manual for questions concerning engine maintenance and repairs.

Non-engine parts require little maintenance. Keep generator clean. Use a damp cloth to clean outside surfaces. Never use water to clean generator. Water can cause damage to internal parts. Use vacuum to clean air inlet and outlet louvers of alternator.

STORAGE

WARNING: Remove all fuel from fuel tank before storing gen- erator. Store fuel in approved con- tainer. Store fuel in a well-vented area free of open flames or sparks.

WARNING: The muffler be- comes very hot during operation. The muffler remains hot for a while after shutdown. Let engine cool before storing.

IMPORTANT: Keep generator level while in storage. Never store generator upside down or standing on end.

Note: We supply the engine owner’s manual with generator. Refer to that manual for questions concerning engine storage.

Use a fuel additive, such as STA-BIL®or an equivalent, when storing generator with fuel in fuel tank. This will minimize fuel gum deposits from forming in engine.

Cover and store generator in a clean, dry place. Do not expose generator to extreme high or low temperatures during storage.

TROUBLESHOOTING

Note: See engine owner’s manual for en- gine troubleshooting.

WARNING: Only a qualified electrical service person should service and repair generator. Use only factory approved replacement parts.

OBSERVED PROBLEM POSSIBLE CAUSE REMEDY

No voltage when starting generator with no electrical load

1.	Defective capacitor	1.	Replace capacitor
2.	Winding short circuit or loose	2.	Check resistance of coils (see Electri-
	connections		cal Component Specifications, page 15)
3.	Defective rotor diode	3.	Replace both diodes on rotor
4.	Loss of residual magnetism	4.	Apply 12-volt battery to capacitor ter-
			minals for 2-3 seconds

Voltage is less than normal voltage with no electrical load

1.	Engine speed too low	1.	Set engine speed to 3720 RPM (62 Hz)
			with no load
2.	Defective rotor diode	2.	Replace both diodes on rotor
3.	Partial short circuit in winding	3.	Check resistance of coils (see Electri-
			cal Component Specifications, page 15)
4.	Defective capacitor	4.	Replace capacitor

Voltmeter reading more than 10% high with 1. Engine speed too high	1. Set engine speed to 3720 RPM (62 Hz)
no electrical load	with no load

Voltmeter reading correct with no electrical load, but more than 10% low when electri- cal load is added

1.	Defective rotor diode	1.	Replace both diodes on rotor
2.	Electrical load too high	2.	Do not overload generator
3.	Engine not running properly	3.	Contact an authorized engine service
			center

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